Multiple component insertion apparatus

ABSTRACT

An insertion apparatus having an insertion head automatically adjustable to simultaneously insert a plurality of axial lead components having body portions of variable diameter and lengths.

United States Patent Ragard Mar. 12, 1974 [5 MULTIPLE COMPONENTINSERTION 2,808,587 10/1957 Hancock 227/2 APPARATUS 2,961,027 11/1960Ullmon et a1. 227/2 X [75] Inventor: Phillip A. Ragard, Binghamton,

[73] Assignee: Universal Instruments Corporation, Binghamton, NY.

[22] Filed: Sept. 13, 1972 [21] App]. No.: 288,494

[52] 11.5. C1. 227/2, 227/90 [51] Int. Cl B27f 7/06 [58] Field of Search227/2, 90

[56] References Cited UNITED STATES PATENTS I 3,539,086 11/1970 Ragard227/2 Primary Examiner-Granville Y. Custer, Jr. Attorney, Agent, orFirm-Fidelman, Wolffe, Leitner & Hiney [57] ABSTRACT An insertionapparatus having an insertion head automatically adjustable tosimultaneously insert a plurality of axial lead components having bodyportions of variable diameter and lengths.

8 Claims, 12 Drawing Figures slvssLssa PATENIED MR 1 2 0974 SHEU 1 0F 5PATENIEDHARIZ mm 37963653 so In A FIG. 7

al'rssissa PATENTEU MR 1 2 I914 SHEET 5 BF 5 F/G. 6B

FIG. 60

MULTIPLE COMPONENT INSERTION APPARATUS This invention is directedtowards an improved insertion apparatus for axial lead components andmore particularly to an insertion apparatus having an insertion headadapted to be automatically adjusted to accommodate axial leadcomponents having body portions of varying diameters and lengths and toinsert a plurality of these into a printed circuit board or the like.

It has been proposed to feed tape carried axial lead components to aninsertion head, which is adapted in sequence to sever the leads of apresent component in order to separate each component from a pair ofspaced carrier tapes; bend the severed leads at right angles to the axisof the separated component; and finally drive the bent leads intopreformed apertures provided in a circuit board disposed below theinsertion head.

Prior insertion apparatus of this type employ fixed insertion heads,wherein the component lead severing, bending and driving toolsincorporated within the insertion head are not relatively adjustable,and include taped component feeding mechanisms which are adapted toaccommodate carrier tapes having a preset spacing between components.Thus, a given fixed insertion head is required to insert all componentsinto a circuit board on a fixed lead center, designated as CD, i.e. thedistance between the axes of inserted leads or center distance,regardless of the body lengths of such components, and with a fixedspacing between the board surface and the axis of the componentsregardless of the component body diameter or thickness. Also, withpresent fixed head apparatus, it has not been possible to insure properorientation of the component leads with respect to preformed circuitboard apertures regardless of lead diameter, or to selectivelyaccommodate carrier or supply tapes having variable spacing betweencomponents. A major drawback in these prior devices has been the lack ofability to insert several components at once, thus saving manufacturingtime and wear and tear on the machine itself.

The limitations inherent in fixed insertion head apparatus not onlylimit the maximum possible density of components on a given board, butseverely limit the versatility of circuit board design and terminalarrangement and require many more shifts of the insertion head tocomplete the insertion functions.

Accordingly, it is a primary object of the present invention to providean insertion apparatus which overcomes the abovementioned disadvantages.

In accordance with the present invention, .there is provided aninsertion head having a pair of insertion head sections which arerelatively adjustable, so as to permit several components to be insertedinto a board on any desired lead center or CD. The ability of theapparatus to insert several components simultaneously on variable leadcenters not only permits versatility of circuit board design andten'ninal arrangement, but permits maximum circuit board density due tothe fact that the lengths of the non-deformed portions of the leadswhich are arranged parallel to the surface of the circuit board mayalways be maintained at a minimum. Further, by permitting relativeadjustment of the head sections, the leads of the components, regardlessof lead diameter or size, may be accurately positioned with respect topreformed apertures provided in the circuit board.

The present invention additionally contemplates the fonning of aninsertion head in such a manner that the extent of travel of the drivingtools of the inserter may be varied to obtain one of a number ofpreselected insertion positions, which are determined by the bodyportion diameters or thicknesses of the components to be inserted. Thisarrangement permits each component, when inserted, to be positioned inproper supporting engagement with the surface of the circuit board andpermits the driving tools of the insertion head to be positioned asclose to the surface board as possible in order to insure properclinching of the inserted leads.

The insertion apparatus of the present invention also includes anadjustable tape feeding arrangement, which permits the apparatus toprocess component carrier tapes having either standard nominal 200 or375 thousands spacing between individual components or to accommodatetapes having variable component spacings along a given carrier tape.

The insertion apparatus of this invention permits the insertion of aplurality of components with a single cycle of the insertion head whichreduces the number of shifts the insertion head has to make to completean insertion operation on any given circuit board. The apparatus is animprovement over the apparatus shown in United States Letters Pat. No.3,539,086 issued on Nov. 10, I970.

The details and mode of operation of the insertion apparatus of thepresent invention will be more clearly understood by reference to thefollowing specification taken with the accompanying drawings, wherein:

FIG. 1 is a front elevational view of the insertion apparatus accordingto the present invention, having parts broken away for purposes ofclarity;

FIG. 2 is an exploded view of the various components of the insertionapparatus;

FIG. 3 is a perspective enlarged view of one of the components of theapparatus;

FIG. 4 is a sectional view taken generally along the line 4-4 of FIG. 1;

FIG. 5 is a side elevational view taken generally along the line 5-5 ofFIG. 1;

FIGS. 6A-6E are views showing the successive steps in the component leadsevering, bending and insertion sequence;

FIG. 7 is a sectional view of the lead forming components of theapparatus showing the relationship with a typical comp0nent;.

FIG. 8 .is a view generally illustrating the alignment of the headcomponents and the tapes and components.

The insertion apparatus of the present invention, which is generallydesignated as 10 in the drawings, is adapted to process axial leadinsertion tapes of the type shown in FIG. 1, wherein a pair of spacedcarrier tapes 1,2 are employed to lead support a plurality of components such as C,, C C C C C,,, which are disposed in a spaced apartrelationship along the length of the tape. The axial lead components aregenerally shown in the drawings as having body portions and a pair ofleads such as 3 and 4, which extend axially from opposite ends thereof.For purposes of reference, the body portions are considered as having alength measured between the opposite ends thereof and a thicknessmeasured in a direction normal to the axes of leads 3 and 4. Further, itwill be understood that the components to be processed may be of varyingbody portion thicknesses and lengths, as indicated in FIGS. 1 and 8.

As in the case of conventional fixed head insertion machines, theapparatus of the present invention is adapted in sequence to feed theinsertion tapes; sever a plurality of leads such as 3 and 4 ofsuccessively presented groups of components in order to separate thepresented components from tapes 1 and 2; deform the free end portions ofthe severed leads to provide generally L-shaped leads; and insert thedeformed leads into preformed apertures such as 8 and 9 (FIGS. 6D and613) provided in a circuit board designated as CB. After insertion ofthe deformed leads, the free ends thereof, which project below circuitboard CB, may be clinched to retain them in insertedv position by anysuitable clinching mechanism (not shown).

Circuit board CB can be adjustably positioned below the insertionapparatus by any conventional supporting apparatus, which is adapted tobe driven in X,Y directions by electric motors. A brief description of asuitable clinching mechanism appears in US. Pat. No. 3,539,086.

Referring to FIG. 1, it will be seen that apparatus 1 generallycomprises an open framework which includes a generally U-shaped metalcasting 14 having vertically disposed backwall portion 13 and legportions 11,12. Leg portions 11,12 are provided with aligned boreopenings adapted to support a plurality of spaced parallel shaftsincluding insertion head drive shaft 15; insertion head transverse guideshafts 16 and 55; insertion head transverse adjustment screw shaft 50having oppositely threaded equal pitch screw sections; insertion tapeadvancing shaft 20; and insertion head support return shaft 80 (FIG. 5).Leg portions 11,12 are further shown in FIGS. 1 and 4 as having mountingflange portions such as 65 which may be suitably affixed thereto, as bywelding.

The structural arrangement of the apparatus thus far described isadapted to support an insertion head assembly, generally designated as100; a component tape guide and feeding assembly which is adapted topresent a component to head assembly 100 for processing once during eachoperational cycle of the apparatus; and an insertion head actuatingmechanism, having air cylinder 41 and adapted to operate assembly 100each time a component is presented thereto.

Insertion head assembly 100 is shown particularly in FIGS. 1 and 2 asincluding a pair of relatively spaced apart insertion head sectionswhich are of mirror image construction and disposed on opposite sides ofa vertically extending reference plane.

The sections are shown particularly in FIGS. 1 and 2 as including basecasting members 101,102, which are adapted to slidably support leadsevering, forming and driver subassemblies and pivotably supportcomponent lead support subassemblies.

Base casting members 101 and 102, particularly in FIGS. 1 and 2, haveball bearing sleeve inserts such as 104 for member 101 (See FIG. 4) and185 and 186 for member 102, which are adapted to slidably receive guideshafts 16 and55, respectively. Insert such as 187 in member 102, isadaptedto threadably receive screw shaft 50. It will be understood byviewing FIG. 1 that such inserts as 187 of base casting members 101,102cooperate with the oppositely threaded screw shaft sectionsrespectively, such that upon rotation of screw 50 insert head sections101,102 are forced to slide on shafts 16 and 55 in opposite directionswith respect to the center plane of the apparatus. Rotation of screwshaft 50 in the opposite direction forces head sections 101,102 to movethrough equal distances either towards or away from the reference planeand may be effected by any suitable means, such as a motor M, mounted oncasting leg portion 12.

Again referring to FIGS. 1 and 2, it will be seen that the facingsurface portions of the base castings 101, 102 are cut out to providelengthwise extending slots 107,182 having bottom walls and side walls.The facing surface portions are further provided as shown particularlyin the case of base casting 102 with a first slot side opening recess161 which is adapted to receive a forming tool cam plate 161 having acamming recess 162; a second slot side opening recess 193, which isadapted to receive severing tool cam plate 189 also having a cammingrecess; a third slot side opening recess 188, which is adapted toreceive the lead support subassembly 144; and a bottom edge slot whichis adapted to slidably receive support subassembly return pin Suitableretention plates 183 and 184 are affixed to the base casting member 102by machine screws for the purpose of maintaining cam plates 161,189 andthe subassemblies in position. A generally L-shaped bracket 190 which ismounted on base casting member 102 by machine screws 192 engaging holes191 cooperates with retention plate 184 to maintain return pin 115within the edge slot.

In FIGS. 1, 2 and 3, the support subassembly 127 is shown as including apivot arm 130 having a pivot pin shaft 128 affixed adjacent the upperend thereof; a lead severing block 129; and a lead support block 142.Blocks 129 and are suitably affixed on opposite sides of the lower orother end 140 of pivot arm 130, as for instance by means of machinescrews. Preferably, the upperwardly facing surface 136 of severing block129 is disposed vertically above the upwardly facing surface 137 ofsupport block 142 a distance corresponding to the maximum thickness ordiameter of the leads of components to be severed, as generallyindicated in FIG. 6A. This insures that the component leads will besevered prior to the initiation of the defonning operation in order toprevent undue stressing of the leads. Pivot arm is beveled as at 131,132, 133, 134, 139, and 143 to allow it to swing without engaginganother portion of the apparatus. Severing block 129 has a groove 138thereon.

The support subassembly 144 is adapted to be pivotally supported withinbase casting member recess 188 by means of pivot pin 146, whose ends arereceived respectively within bore opening 188' of base casting member102, shown only in FIG. 2 and a bore opening of retention plate 184 (notshown). When thus supported, subassembly 127 is adapted to be normallymaintained in its supporting position, illustrated in FIGS. 1, 2 and6A-6E by means of an assembly shown in FIG. 4 as including return pin84; abutment 82 carried on return shaft 80; and a tension spring 206(FIG. 5), which has its respective ends affixed to leg portion by pinsupport 207, and return shaft 80 by pin 205. Preferably, subassembly 127is prevented from being pivoted in a clockwise direction past itssupporting position, as viewed in FIG. 4, due to the operation oftension spring 206, by abutting engagement with severing member 110,forming member 120 and driver 150. It will be understood that abutment82 and also the corresponding abutment for return pin 115, which is notshown in the drawings, is of sufficient length in a direction measuredaxially of shaft 80 to insure engagement thereof with return pins 84,115', in all adjusted positions of head sections 101,102, respectively.

Support assembly 127 is provided with beveled surfaces 132 and 133,which are adapted to cooperate with the rest of the apparatus in themanner to be hereinafter discussed, for the purpose of pivoting theassembly from its operative or component supporting position, as viewedin FIG. 4, in a counterclockwise direction into an inoperative positionto permit the insertion subassembly to move downwardly towards circuitboard CB into a component lead insertion position. In this respect, itwill be apparent that when subassembly 127 is pivoted in acounterclockwise direction, return pin 84 is forced to slide within slot84' thereby forcing abutment 82, and return shaft 80 to move in acounterclockwise direction, also as viewed in FIGS. 4 and 5, and placingspring 206 under increased tension.

The lead severing, forming and driver subassembly is shown particularlyin FIGS. 1 and 2 as including a lead driving member 150 having adetachable driving tool 155 disposed adjacent the lower end thereof; alead forming member 120 having integrally formed abutment 126 andforming tool 121 disposed adjacent the upper and lower ends thereof,respectively; a lead severing member 110 having an integrally formedabutment 113 and severing tool 111 disposed adjacent the upper and lowerends thereof, respectively; and forming and severing member cam pins 119and 163, respectively.

More specifically, the driving members 150 and 160 are shown as havingside wall surfaces in which are disposed lengthwise extending slots151,166 adapted to slidably receive forming members 120 and 170,respectively, and severing members 110 and 180, respectively which arearranged in a juxtaposed relationship. Further, the driving members 150and 160 are each provided with a pair of relatively off-set slots152,153, and 167 (second slot not shown), respectively, which extendtransversely from slots 151,166 through member front and rear wallsurfaces and are adapted to slidably receive cam pins such as 118, 119,176, and 163, respectively. It will be understood that when cam pin 119is slidably disposed within slot 153, its curved end portion is adaptedto be selectively projected through the front wall of 150 for thepurpose of cooperating with the camming recess 125 of cam plate 124, andits wedge-shaped end is adapted to be selectively projected into slot151 for the purpose of cooperating with V-shaped slot recess 118provided in severing member 110. In a like manner, cam pin 118' isprovided with a curved end portion which is adapted to be selectivelyprojected through the rear wall surface of 150 into cooperatingengagement with recess 116 of cam plate 1 and its wedge shaped portionis adapted to selectively project into slot 152 into cooperatingengagement with a V-shaped slot 119' provided in lead forming member120.

When the insertion subassembly is slidably positioned within basecasting member slot 107, the driving member side wall surface and theoutwardly facing side surface of severing member 110 are disposed insliding surface engagement with the bottom wall of slot 107 and drivingmember front and rear wall surfaces are disposed in sliding surfaceengagement with the side walls of slot 107. When the insertionsubassembly is thus positioned, camming surface 159 of driving member isoperatively aligned with cam follower surfaces 132 and 133 of supportassembly 127 and driving tool 155, forming tool 121 and severing tool111 are positioned with respect to severing block 129 and support block142 of support assembly 127 in the manner indicated in FIG. 6A.

Tools 111, 121 and are shown primarily in FIG. 2 as being provided witha plurality of aligned, generally V-shaped downwardly opening slots 112,123 and 157 respectively which are adapted to receive leads such as 4 ofcomponent C,. Also, it will be seen that the surface of tool 155 isdisposed in a facing relation with respect to the reference plane and ismachined away, as at 156, to afford clearance between the driving tooland the body portion of the component. Further, forming tool 121 has aplurality of lead receiving and guide slots such as 175 in tool 173 ofmember which extends upwardly from adjacent V-shaped groove 123, isdisposed on the surface of tool 121 disposed in sliding engagement withtool 155, and is machined away as at 122 on the surface thereof whichslidably engages severing tool 111 in order to maximize clearancebetween the forming tool and the leads of a component which has beenpreviously inserted into board CB.

Lead forming members 120 and 170 and lead severing members 110 and 180are normally biased in a vertically downward direction by means oftension springs such as 44, 45 46 and 46' (FIG. 1). The tension springsmay be suitably afi'lxed adjacent the lower ends thereof to anyvertically stationary part of the apparatus, such as base castings101,102 and adjacent their other or upper ends to pins 181, 171, 126 and114 carried on lead forming member and lead severing member abutments178, 172, 126' and 113, 178, respectively.

Lead severing member 180 has a plurality of notches such as 179,corresponding to the number of slots such as and guides such as 165 ontools 173 and 164 of members 170 and 160, respectively. Drive members160 has transverse notches such as 167 which act, together with camssuch as 163,176 in the same manner as cams 119, 118 and slots 152,153.V-shaped notch 177 in severing member acts in the same manner as notch118. Camming surface 168 of drive member 160 acts like surface 159 ofmember 150. Tool 173 is machined away as at 174.

Support member 144 is identical to 127 and has pin 146, upper portion145 and support and severing blocks 148 and 147 attached thereto byscrews 149.

The operational sequence of the insertion head assembly will best beunderstood by reference to FIGS. 6A-6E. Only one-half of the assemblieswill be described since it is understood that they are mirror images. InFIG. 6A, the insertion members are shown as being in their upperposition and support assembly 127 is shown as being in its operating orcomponent supporting position, wherein a component C, is supported bylead 4 on the upwardly facing surface 136 of shear block 129 withV-shaped slots 112,123,157 of members 110,120 and 150, respectively,disposed above and in alignment with component leads 4.

Referring again only to one half of the subassembly for purposes ofbrevity, it will be understood that in the up position shown in FIG. 6A,the wedge-shaped end of cam pin 119 is maintained in slot recess 118 ofsevering member 110 by engagement of its curved end portion with basecasting 101 through slot 153 in member 150 in order to lock severingmember 110 for movement with driving member 150. Further, thewedgeshaped end of cam pin 118' is maintained in slot recess 119' offorming member 120 by engagement of its curved end portion with basecasting 101 through slot 152 in order to lock forming member 120 formovement with driving member 150.

Thereafter, when driving member 150 is driven downwardly in the mannerto be described, tool 11 1 of severing member 110 is driven downwardlyinto engagement with component lead 4 and below the upwardly facingshear block surfaces 136 to effect severing of the lead, whereupondownwardly moving forming member tool 121 is positioned in engagementwith the severed lead to maintain such lead tight against upwardlyfacing support block surface 142. Immediately thereafter, downwardmovement of severing member 110 is terminated, due 'to engagement ofmember abutment 113 with base casting 101; the severing member beingdisconnected from driving member 150, due to the presence of severingtool cam plate recess 125, which permits cam pin 119 to ride out of slotrecess 118. This arrangement prevents interference of severing tool 111with previously inserted components.

After termination of severing tool member travel, forming tool 121 anddriving tool 155 are moved into the position shown in FIG. 6C, whereatforming of an L-shaped lead has been completed with the free end of suchlead preferably projecting downwardly below the end of the guide slot(such as 175) and the driving tool has been placed in engagement withthe non-deformed or horizontally extending portion of the L-shaped head.

Upon continued downward movement of tools 121,155, support assembly 127is removed from its operable position by the action of driving membercam surface 159 to permit free movement of the tools towards theinsertion position shown in FIGS. 6D and 6E, wherein the free ends ofthe deformed leads 3 and 4 are inserted into the board apertures 8 and9.

Preferably, tools 121, 155 move together until tool 121 is immediatelyadjacent the surface of circuit board CB (as in FIG. 6D) to insureaccurate insertion of the lead, whereafter movement of tool 121 isterminated due to engagement of forming member abutment 126' with basecasting 101; forming member 120 being disconnected from driving member150, due to the presence of forming tool cam plate recess 116, whichpermits cam pin 118' to ride out of slot recess 119'. Thereafter, tool155 continues its downward movement in order to drive the leaddownwardly through the forming member guide slot (See 123, in FIG. 8)into fully inserted position as shown in FIG. 6E.

It will be understood that although the insertion position of drive tool155 may be varied to compensate for variable component body portionthicknesses or diameters, as will hereinafter be described, theinsertion position of forming tool 121 is constant since it dependssolely on the positioning of forming tool cam plate recess 116. Thus toaccommodate various diameter component body portions during oneinsertion routine, a single drive tool 155 may be provided with Vgrooves 157 of difi'erent depths. The tool head 155 is detachablysecured to the driving member 150 by screws 155'. With this structure,an infinite array of sequenced components may be inserted, the onlymodification to the machine being the substitution of a different toolhead 155 having the requisite V grooves 157 to accommodate the newcomponent diameters.

It is also understood that in a single cycle a plurality of componentshave been inserted. Referring to FIG. 8, it is seen that members 110,120and 150 span six components and they are all acted upon simultaneously.

Upon return movement of driving member 150, spring 44 functions toinitially constrain movement of forming member 120 therewith due tofrictional forces, until cam pin 118 is returned into alignment withforming members slot recess 119, whereupon cam pin 118 is forced to ridout of forming tool cam plate recess 116 and be forced back into slotrecess 119. In a similar manner, spring 45 functions to constrainsevering member 110 until cam pin 119 is again aligned with slot recess118 whereupon the cam pin 119 is forced back in slot recess 1 18 as itis forced to ride out of severing tool cam plate recess 125.

The purposes for employing motor driven screw 50 to simultaneously forceinsertion head sections 101,102 to move in opposite directions withrespect to the reference plane will now become apparent from viewingFIGS. 6C, 6D and 7.

Turning to FIG. 8, it will be understood that the lengths of the bodyportions of presently available components may vary substantially, andthus a conventional fixed head inserter designed to handle only C cannotaccommodate C C C etc. due to limited spacing between driving tools and160. Altematively, if a fixed head inserter were designed to accommodatethe larger sized component, not only is the number of components whichmay be inserted in a given board greatly reduced, but problems of leaddamage are offtimes encountered when small sized components areinserted, due to excessive lengths of exposed above the board surface.By providing'for selective adjustment of the insertion head inaccordance with the present invention, not only may circuit boarddensity be maximized but where desired, the leads of the components maybe inserted at board terminal positions specified by a circuit boarddesigner.

In FIG. 7 there is illustrated a problem offtimes encountered with fixedhead inserters, when employing components having leads which varysubstantially in diameter. conventionally, for purposes of convenienceand to maximize board strength, the size or diameter of all apertures 8,9 for any given board is the same, apertures are positioned on the sameC.D. (center distance), and the apertures are only slightly larger thanthe maximum lead diameter expected to be employed. Thus, it has been thepractice with fixed head inserters to set the spacing between formers120,170 so as to position the smallest diameter lead encountered, e.g.250 shown in section, as closely adjacent opposite facing sides ofapertures 8, 9 as possible, with a view to centering large diameterleads eg 251, shown in phantom, within the apertures. However, as willbe apparent from viewing FIG. 7, this procedure often results inimproper positioning of large diameter component leads, whose effectiveC.D. may be significantly smaller that the effective CD. of leads250. Byutilization of the present invention, the spacing between formingmembers 120,170 may be varied to obtain a desired C.D. such as X or Yregardless of component lead diameter, and thus insure accurateorientation of the leads with respect to the board apertures. Thisselected CD. is the same for all six components being simultaneouslyinserted.

The insertion tape guide and feed assembly includes as in the case ofinsertion head assembly, a pair of guiding and feeding sections whichare of mirror image construction and disposed on opposite sides ofapparatus reference plane. Referring to FIGS. 1, 4 and 5, it will beunderstood that the sections are mounted on framework mounting flangeportions such as 65 for adjustment relative to the apparatus referenceplane by means of brackets having first and second flange portions suchas 66 and 71. Bracket flange portions 66 may be locked in a desiredadjusted position by means of clamping bolts 69 and washers 68 which arefreely received within bracket flange slots such as 67 and threadedlyreceived within mounting flanges 65.

By now referring particularlyto FIGS. 4 and 5, it will be seen that thesections are provided with generally L-shaped lead guides 76 which arepivotally affixed to bracket flanges 66 by means of pin shafts 72. Theguides are adapted to be maintained in the position illustratedparticularly in the case of guide 76 in FIG. 1 by means of thumb screws74 which are threadably received within bracket flange portions 66.Referring particularly to FIG. 4, it will be understood that thesections are also provided with stationary guides, shown only in thecase of guide 77, which are adapted to coop erate with pivotal guides 76to define a vertically extending component lead guide passageway 89.

Now referring to FIGS. 1 and 4 and particularly to the right-handassembly section, it will be seen that flange portion 60 is bored toreceive a bearing insert 59 in which is journalled a shaft having acomponent lead advancement wheel 61 carried thereon. As will be clearlyseen by reference to FIG. 1, advancement wheels of each section areprovided with radially extending annular rim portions such as 6 having aplurality of circumferentially spaced generally V-shaped lead receivingslots, which are disposed in alignment. The lower ends of pivotableguides such as 76 form continuations of the upwardly facing surfaces ofsevering blocks 129 and 147 and serve to maintain the component leadswithin the slots, as successive components are presented to theinsertion assembly by rotation of advancement wheels such as 61.PreferablY, the spacing between the slots corresponds to the minimumstandard spacing between components on tape 1 and 2.

It will be noted at this point that the assembly sections may beadjusted with reference to the apparatus reference plane, so as topermit adjustment wheel rim portions to engage the relatively inwardlyfacing marginal edges of component carrier tapes 1 and 2 and therebyeffect positioning of the components carried by such tapes in properorientation with respect to apparatus reference plane, and thus sections101 and 102 of the insertion head assembly. Also, it will be noted thatthe insertion section base castings 101 and 102 are each cut out, as at106, to freely receive the component advancement wheels in order topermit relative adjustment of sections 101, 102 after the distancebetween the sections has been set for a given width carrier tape.

Component lead advancement wheels may be simultaneously rotated to drawinsertion tape 1 and 2 downwardly through the lead guide slots byratchet assemblies shown only in detail in U.S. Letters Pat. No.3,539,086 which is hereby incorporated as a part of this specfication byreference. It consists of member 48, pin shaft 53, pivot member 54,ratchet paw 51, pivot member pivot pin shaft 52 and ratchet sleeve 56.

Now referring to FIG. 5, it will be understood that one end of shaft 20projects outwardly beyond leg portion 11 and is adapted to carry flangeportion 232, which is movably connected to piston rod 225 of pneumaticcylinder 221 by means of pin shaft 231. The extent to which piston rod225 may be retracted into cylinder 221 upon operation thereof and thusthe angle through which shaft 20 is rotated is controlled by a stopblock 226, which is adapted to engage the undersurface of piston shaftnut 229. Stop block 226 may be moved from the position shown in FIG. 5in order to permit piston rod 225 to be fully retracted, by looseninglocking bolt 228, which is slidably disposed in stop block slot 227 andthreadably received within framework leg portion 11. Flange portion 232carries a cap portion 233 secured thereto by bolts 234. Cylinder 221 isheld in place by machine screws 224 and bracket 223.

By viewing FIG. 1, it will be understood that when piston rod 225 isretracted into engagement with stop block 240, ratchet paw 51 is steppedbackwardly one tooth on the ratchet wheel whereas without the stop blockin the position, full retraction of piston rod 236 will cause ratchetpaw 51 to step two ratchet teeth. Since the number of ratchet teethstepped while cocking the ratchet assembly determines the degree offeeding rotation of advancement wheels such as 61 when cylinder 221 isactuated to extend rod 225, the number of ratchet teeth corresponds tothe number of slots 6 on advancement wheel 61 and the spacing betweenadjacent wheel slots corresponds to the minimum nominal spacing forstandard carrier tapes. It will be apparent that stop block 226 maybe-employed to adjust the apparatus to handle insertion tape s havingeither standard nominal 200 thousands or 370 thousands spacing betweencomponent leads. In this respect, it will be understood that spacingsbetween component leads of such standard tapes actually approximate 195thousands and 390 thousands, respectively. If desired, tapes havingvariable component spacings to conserve tape length where both extremelylarge and relatively small diameter components are to be employed, maybe accommodated by employing remotely controlled means to adjustablyposition stop block between insertion cycles.

Limit switch 63 and roller 64, shown in FIG. 1 as being carried in legportion 12, are employed to sense clockwise rotation of shaft 20 whichresults in rotation of advancement wheel 61 to present a component tothe insertion head.

Referring particularly to FIGS. 4, and 5 it will be understood thatdriver members 150,160 may be simultaneously reciprocated within basecasting slots 107,182, to move from their first or uppermost position,into their second or lowermost component lead inserting position bymeans of actuating assembly connected to cylinder 41.

This actuating mechanism includes a generally U- shaped driving bracketwhich is fixed for rotation with drive shaft 15 and provided with ahalf-round driving pin 92 adapted to be slidably received withintransversely extending cutouts such as 169 of driver members 150,160; astop bracket 37, which is fixed for rotation with one end of drive shaft15 projecting outwardly through leg portion 11; and a double actingpneumatic cylinder 41. Cylinder 41 is mounted on leg portion 11 by abracket 31,32 and includes a piston rod 33 having a connecting pin 38which is slidably received within stop bracket slot 200. By viewing FIG.5, it will be apparent that when cylinder 41 is actuated to retractpiston rod 33, stop bracket 37 is pivoted in a counterclockwisedirection into the position indicated in phantom to effect drivingrotation of drive shaft 15 and thus, reciprocation of drive members150,160 towards their insertion position.

The other end of drive shaft 15, which is shown in FIG. 1 as projectingoutwardly through leg portion 12, has a flange 22 adapted to carry apair of cam members such as 23 secured by screws 28. Cam members 23 areadapted to cooperate with limit switches 29 and 30, respectively whichare mounted on leg portion 12 by brackets such as 21 and are employed toindicate to a control circuit of the insertion apparatus that theinsertion subassemblies are in either their uppermost or insertionpositions. Cam 23 engages a roller 24 held in yoke 26 by pin of switch30. In FIG. 5, stop bracket 37 is shown as being provided with a pin 39,which is adapted to be slidably received within slot 202 providedadjacent one end of a connecting rod 40. Connecting rod 40 is pivotablysupported adjacent the other end thereof by a pin shaft 203, which issupported on bracket 204 affixed for rotation with return shaft 80. Thisarrangement serves, after component lead supporting subassemblies 127and 144 have been initially pivoted towards their inoperative positionsby drive member cam surfaces 158,168, to temporarily rotate return shaft80 in a counterclockwise direction, as viewed in FIG. 4 and thustemporarily remove abutments such as 82 from positive engagement withreturn pins 84. Accordingly the insertion subassemblies are freed of thereturn bias of spring 206 in order to permit drive members 150,160 toslide on pivot arm cam surfaces 132,133 FIG. 3) with a minimum amount offriction, as the drive members are reciprocated to and from insertionposition. Upon the return of stop bracket 37 to its original or fullline position shown in FIG. 5, connecting rod 40 is rendered inoperativein order to permit spring 206 to return support assemblies 127,144 totheir original supporting positions.

Further, in accordance with the present invention, there is provided amotion limiting mechanism which is generally shown in FIG. 5 andoperates to limit the extent through drive members 150,160 arereciprocated upon actuation of driver cylinder 41. Motion limitingmechanism generally comprises a stop block 209, a ternary pneumaticallyoperated cylinder (not shown) and an endless chain 218 which is adaptedto transform reciprocating movement of the ternary cylinder intorotational movement of stop block 209.

Stop block 209 is freely mounted for rotation on guide shaft 16 by aball bearing insert 208 and includes a plurality of threadablyadjustable stop elements, 210, 211, 212, 213, 214, 215, 216, 217 whichare spaced equally about the periphery of stop block 209. The stopelements may be individually adjusted with respect to a zero referencesurface which is defined by a set block or gauge 219 mounted on legportion 11 by machine screws 220. Preferably one of the stop elements,as for instance, element 210, is adjusted to provide a minimum referencedistance between such element and the reference surface and another ofthe stop elements, as for example, element 217, is adjusted to provide amaximum reference distance between such element and reference surface ofblock 219. Thereafter, the remaining stop elements are adjusted withrespect to the reference surface so as to provide for instance an equaland progressive variation between the minimum and maximum referencedistances.

The number of stop elements provided for any given insertion apparatusand the reference distances for which they are individually adjustedwill depend on the number of different insertion positions into which itis desired to drive members 150,160, such insertion positions i.e. thedistance between the tools 155,164 and the surface of the circuit boardCB in turn depending on the body diameters of the respective componentsto be inserted. Thus, if a plurality of maximum diameter components areto be inserted, e.g. component C of FIG. 1, stop element 210 adjusted tominimum reference distance would be positioned in the reference stopposition shown in FIG. 5 to permit it to be engaged by a projection 201of stop bracket 37 when the latter is pivoted into its phantom linedriving position. Since stop element 210 will permit the minimum degreeof stop bracket pivotable movement, it follows that drive members150,160 are driven through a minimum distance, so as to permit maximumspacing. If, on the other hand, a minimum diameter component is to beinserted, a stop element would be moved into the reference stop positionin order to maximize the degree of stop bracket movement.

By permitting the insertion position of the drive members to be varied,the positioning of drive member tools 155,167 is optimized for any givencomponent size from the standpoint of proper lead clinching. Further,the body portions of the components may be placed in desired supportingengagement with the surface of a circuit board regardless of bodyportion thickness. The ternary cylinder and its operation are explainedfully in US. Pat. No. 3,539,086.

OPERATION In operation, a suitable memory element, such as a punched ormagnetic tape, is coded to indicate the various component and circuitboard parameters for each of the sets of components to be supplied tothe insertion apparatus during fabrication of a given circuit board.Thus, for each group of components to be inserted, the tape is coded toindicate a given X-Y board position, a given CD. or distance between thecomponent lead axes of a given diameter which is required in order topermit the leads to be properly inserted into prepunched boardapertures, and the diameter or thickness of the body portion of thecomponent.

The coded tape, not shown, is then employed to control operation of thecontrol circuit of the apparatus.

Operation is initiated by feeding the coded tape in a stepwise mannerpast a suitable tape reader which signals a control mechanism to begin acomponent insertion cycle. The control initiates the insertion cycle byactuating circuit board supporting table positioning motors (not shown)to drive the circuit board into a given X-Y position, whereat a set ofprepunched board apertures are disposed in alignment beneath theinsertion head assembly.

The two halves of the insertion assembly are adjusted relative to eachother by screw shaft 50 to accommodate the C.D. of the next group ofcomponents to be inserted. Similarly, stop block 209 is rotated toaccommodate the diameter of the body portion of the next group ofcomponents. The component advancement wheel 61 is advanced by actuationof cylinder 221 one to six times to define the number of components tobe simultaneously inserted. The components rest on support assemblies127 and 144, which are in their forward position.

Upon actuation of cylinder 41, the drive members 150 and 1611 arelowered, carrying with them severing members 110,180 and forming members120 and 170, respectively. The plurality of components (in the presentdevice, from one to six) have their lead severed, formed and insertedinto a series of apertures in a circuit board as displayed in FIGS.6A-6E. After the leads are severed and formed, support assemblies 127and 144 pivot out of the path of drive members 150 and 160.

Upon deactivation of cylinder 41, the drive members 150 and 160 andtheir associated severing members and forming members return to theiruppermost position and support assemblies 127 and 141 pivot back totheir initial positions ready for the next .cycle.

While only the preferred embodiment of the present invention has beendescribed in detail, various modifications thereof and additions theretowill become apparent to those skilled in the art in view of theforegoing description. For example, the machine has been described foruse specifically with axial lead components having single leadsextending from each end thereof while one skilled in the art wouldrecognize that the axial lead component could have more than one leadextending from an end, suitable provision being made in the operatingmechanism to cut, bend and insert the multiple leads of the multiplecomponents. Further, it will likely occur to one skilled in the art thatthe present invention has utility in processing components where it isonly desired to trim and deform components to provide processedcomponents which may thereafter be inserted by other insertionapparatus. There obviously is no limitation on the number of componentsthat may be simultaneously inserted.

Accordingly, the scope of protection for the present invention is to belimited only by the scope of the appended claims.

What is claimed is:

1. An apparatus for processing electrical components each having a bodyportion and a pair of leads extending from opposite ends thereof whichcomprise: a head assembly having first and second relatively spacedapart sections; means adapted to actuate said sections during eachoperational cycle of said apparatus; means adapted to present aplurality of said components to said head assembly during eachoperational cycle of said apparatus in such a manner that the leads ofsaid plurality of presented components are operably positioned oneadjacent each of said sections with said components body portion beingdisposed between said sections, each of said sections when actuatedbeing adapted to sequentially sever lengths from one lead of each ofsaid plurality of presented components to produce a series of shortenedcomponent leads, thereafter deform free end portions of said shortenedleads to produce generally L-shaped leads, and thereafter insert thefree ends of said deformed L-shaped leads into a series of spacedpreformed apertures provided in a circuit board.

2. An apparatus according to claim 1 wherein said component presentingmeans includes two rclatively spaced apart axially aligned feed wheelsdisposed adjacent opposite sides of said head assembly, each said feedwheel having a plurality of equally spaced apart recesses disposedadjacent the periphery surface thereof, said wheel recesses beingarranged to form periphery-spaced pairs of aligned recesses, therespective recesses of each said pair being adapted to engage therespective leads of components to be presented, and means to effectrotation of said feed wheels to present a predetermined number ofcomponents to said head assembly during each operational cycle of saidappara tus.

3. An apparatus according to claim 2 wherein components to be presentedto said head assembly are lead supported by a pair of parallel carriertapes, said feed wheels are provided with radially extending annularguide surfaces, said guide surfaces being adapted to guidingly engagefacing marginal edge portions of said carrier tapes to effect desiredpositioning of said components with respect to said head assembly in adirection lengthwise of each said component body portion between saidends thereof, and means are provided to vary the distance between saidfeed wheels in accordance with the spacing between said facing marginaledges of said tapes.

4. An apparatus according to claim 2 wherein components to be presentedto said head assembly are lead supported by a pair of parallel carriertapes, and said means to effect rotation of said feed wheels includesmeans selectively operable to vary feeding rotation of said feed wheelsin accordance with the spacing between components carried on said tapes.

5. An apparatus according to claim 1 wherein each of said component bodyportions has a thickness when measured normal to a line extendingbetween said ends thereof, said sections include means to insert saidfree ends of said deformed L-shaped leads into said preformed aperturesand means are provided to adjustably vary insertion position of saidinsertion means in accordance with the said thicknesses of saidpresented components.

6. An apparatus according to claim 1 including means adapted to vary thespacing between said sections; and control means operable to actuatesaid section spacing varying means, whereby the distance measuredbetween the free ends of said deformed leads of components processedduring successive operational cycles of said apparatus may be varied ina predeter' mined manner.

7. An apparatus according to claim 1 wherein said section spacingvarying means includes guide means adapted to slidably support saidsections for reciprocation along aligned paths of travel, and shaftmeans aligned with said paths of travel, said shaft means havingoppositely threaded equal pitch screw portions, each said section beingadapted to threadably receive one of said screw portions; and saidcontrol means includes motor means adapted to selectively rotate saidshaft means in opposite directions, whereby said sections are forced toslide on said guide means in opposite directions.

8. An apparatus for processing a series of electrical components, eachhaving a body portion and a pair of leads extending from opposite endsthereof, which comprise: a head assembly having first and secondrelashaped leads and thereafter insert the free ends of said deformedleads into one side of a series of spaced preformed apertures providedin a circuit board; means adapted to vary the distance between saidsections in order to vary the spacing between said free ends of saiddeformed leads; and means to adjustably control operation of saidvarying means in accordance with the spacing between said preformedapertures into which said deformed leads are to be inserted.

1. An apparatus for processing electrical components each having a bodyportion and a pair of leads extending from opposite ends thereof whichcomprise: a head assembly having first and second relatively spacedapart sections; means adapted to actuate said sections during eachoperational cycle of said apparatus; means adapted to present aplurality of said components to said head assembly during eachoperational cycle of said apparatus in such a manner that the leads ofsaid plurality of presented components are operably positioned oneadjacent each of said sections with said components body portion beingdisposed between said sections, each of said sections when actuatedbeing adapted to sequentially sever lengths from one lead of each ofsaid plurality of presented components to produce a series of shortenedcomponent leads, thereafter deform free end portions of said shortenedleads to produce generally L-shaped leads, and thereafter insert thefree ends of said deformed L-shaped leads into a series of spacedpreformed apertures provided in a circuit board.
 2. An apparatusaccording to claim 1 wherein said component presenting means includestwo relatively spaced apart axially aligned feed wheels disposedadjacent opposite sides of said head assembly, each said feed wheelhaving a plurality of equally spaced apart recesses disposed adjacentthe periphery surface thereof, said wheel recesses being arranged toform periphery-spaced pairs of aligned recesses, the respective recessesof each said pair being adapted to engage the respective leads ofcomponents to be presented, and means to effect rotation of said feedwheels to present a predetermined number of components to said headassembly during each operational cycle of said apparatus.
 3. Anapparatus according to claim 2 wherein components to be presented tosaid head assembly are lead supported by a pair of parallel carriertapes, said feed wheels are provided with radially extending annularguide surfaces, said guide surfaces being adapted to guidingly engagefacing marginal edge portions of said carrier tapes to effect desiredpositioning of said components with respect to said head assembly in adirection lengthwise of each said component body portion between saidends thereof, and means are provided to vary the distance between saidfeed wheels in accordance with the spacing between said facing marginaledges of said tapes.
 4. An apparatus according to claim 2 whereincomponents to be presented to said head assembly are lead supported by apair of parallel carrier tapes, and said means to effect rotation ofsaid feed wheels includes means selectively operable to vary feedingrotation of said feed wheels in accordance with the spacing betweencomponents carried on said tapes.
 5. An apparatus according to claim 1wherein each of said component body portions has a thickness whenmeasured normal to a line extending between said ends thereof, saidsections include means to insert said free ends of said deformedL-shaped leads into said preformed apertures and means are provided toadjustably vary insertion position of said insertion means in accordancewith the said thicknesses of said presented components.
 6. An apparatusaccording to claim 1 including means adapted to vary the spacing betweensaid sections; and control means operable to actuate said sectionspacing varying means, whereby the distance measured between the freeends of said deformed leads of components processed during successiveoperational cycles of said apparatus may be varied in a predeterminedmanner.
 7. An apparatus according to claim 1 wherein said sectionspacing varying means includes guide means adapted to slidably supportsaid sections for reciprocation along aligned paths of travel, and shaftmeans aligned with said paths of travel, said shaft means havingoppositely threaded equal pitch screw portions, each said section beingadapted to threadably receive one of said screw portions; and saidcontrol means includes motor means adapted to selectively rotate saidshaft means in opposite directions, whereby said sections are forced toslide on said guide means in opposite directions.
 8. An apparatus forprocessing a series of electrical components, each having a body portionand a pair of leads extending from opposite ends thereof, whichcomprise: a head assembly having first and second relatively spacedapart sections; means adapted to actuate said sections during eachoperational cycle of said apparatus; means adapted to present apredetermined plurality of said components to said head assembly duringeach of said operational cycles in such a manner that the leads of eachof said plurality of presented component are operably positionedadjacent each of said sections with said body portion being disposedtherebetween, each of said sections when actuated being adapted tosequentially deform said plurality of presented component leads toproduce generally L-shaped leads and thereafter insert the free ends ofsaid deformed leads into one side of a series of spaced preformedapertures provided in a circuit board; means adapted to vary thedistance between said sections in order to vary the spacing between saidfree ends of said deformed leads; and means to adjustably controloperation of said varying means in accordance with the spacing betweensaid preformed apertures into which said deformed leads are to beinserted.